Manufacture of pile yarn and of pile carpet made therefrom



Feb. 11, 1958 D. B. PARLIN MANUFACTURE oF PILE YARN AND oF PILE CARPETMADE THEREFROM 4 Shee'cs-Sheei'l 1 Filed Jan. 26, 1953 Feb. 11, 1958 D.B. PARLIN MANUFACTURE 0E PILE YARN AND 0F PILE CARPET MADE TEEREEROM 4Sheets-Sheet 2 Feb. 11, 1958 D. B. PARLIN MANUFACTURE OF' PILE YARN ANDOF PILE CARPET MADE THEREFROM Filed Jan. 26, 1953 4 Sheets-Sheet 3Invezov.-

Feb. 11, 1958 D. B. PARLIN 2,822,605

MANUFACTURE OF PILE YARN AND OF PILE CARPET MADE THEREFROM 4Sheets-Sheet 4 Filed Jan. 26, 1953 nited States Patent O MANUFACTURE FPILE YARN AND OF PILE CARPET MADE THEREFROM vDavid B. Parlin,Thompsonville, Conn., assigner to Bigelow-Sanford Carpet Company, Inc.,Thompsonville, Conn., a corporation of Delaware The present inventionrelates to improvements in the manufacture of pile yarns, and in themanufacture of pile carpet from said yarn.

It is a principal object of the invention to produce a novel pile yarnhaving novel and improved color and wear characteristics for use in themanufacture of pile surface floor coverings or carpets.

More specifically, it is an object of the invention to provide, for usein the manufacture of loop pile surface floor coverings, a pile yarncomposed of a plurality of strands which are enchained with one anotherto form a composite pile yarn of a novel constructionv which isresistant to catching or pulling and which has novel and readilyvariable color characteristics.

It is a further object of the invention to provide a novel and improvedfloor covering of the general type having a backing material and a pilesurface of looped pile yarn which is novel in construction, distinctivein appearance, and possessed of improved covering and wearing qualities,

In accordance with the invention a novel multi-colored yarn is providedwhich is formed of a plurality of strands enchained together by means ofa stitching operation. The operation may be carried out upon an overedgestitcher provided with a chain forming mandrel. The composite pile yarnis formed preferably with long stitches which are tied together by aseries of tightly drawn loops produced by causing a heavy tension strainto be applied against some one of the feeding strands. The pile yarnproduced in this manner has certain outstanding characteristics notfound in knitted yarn or in warp knitted tape constructions. Theenchained yarn here illustrated is so integrated and so rmly bound as tobe resistant to catching or pulling, has no tendency to unravel eventhough any one of the strands may be broken, and further provides for anarrangement of the strands in the completed yarn which producesunexpected and striking color effects. Variation of the tension appliedto the individual strands has been found to produce substantial changesin the proportion of one strand to another in the enchained yarn with acorresponding contrast in the general color effect where two or morestrands of different color are employed.

The novel pile yarn herein described is tufted, woven or otherwisecombined with suitable backing material and has been found particularlyadaptable for this use to form a loop pile surfaced floor covering ofsuperior quality and appearance. The spaced strictures formed by thetightly drawn loops of the more heavily tensioned strand of the yarn,produce a characteristic resiliency and tendency to retain its positionand shape even where relatively soft pile yarns are employed, and impartto the pile loop surface a degree of toughness and resistance to wearmuch greater than that found in the floor coverings of the prior art.The frequent tying-in of the several strands along the length of theyarn effectively over- Patented Feb. 11, 1958 comes any tendency of thestrands to be caught or pulled out under conditions of actual use.

The pile yarn formed in accordance with the present invention,especially where two or more different colors of strands are employed,imparts a unique appearance to the-loop pile surface of the floorcovering which is both distinctive and pleasing. Further variations inappearance of the finished fabric are produced by shifts in theproportions of the different colored strands in the yarn produced by thetensioning of first one and then the other of the individual strands fedto the stitching mechanism for enchaining in a single pile yarn.

Further, in accordance with the invention, the enchained yarn isproduced on an overedge type stitcher having the conventionalstitch-forming instrumentalities, including a needle and over and underloopers, in accordance with a novel method which comprises forming aseries of enchained loops from either two or three feeding strands abouta forming mandrel, selectively increasing the tension applied to one oranother of the feeding strands, and drawing off the chain formed by thestitchforming instrumentalities at a rate which is related to the rateof operation of the stitch-forming instrumentalities, and which therebycontrols the number of stitches per inch of the enchained yarn. f

With the above and other objects in view which may hereinafter appear,the several features of the invention consist also in the devices,combinations, arrangement of parts and in the method above describedwhich together with the advantages to be obtained thereby will bereadily understood by one skilled in the art from the followingdescription taken in connection with the accompanying vdrawings inwhich:

Fig. lis a diagrammatic opened-out Vview of` aneuchained two-strand pileyarn produced in accordance with the present invention andfurther'illustrating the change in yarn structure produced by thetransfer of a relatively heavy tensioning strain from one to anotherstrand; Y

Fig. 1a is a diagramatic opened-out view o f an enchained two-strandpile yarn similar to that shown'in Fig. l, but with the addition of acore yarn;

Fig. 2 is a somewhat diagrammatic opened-out view of an enchainedthree-strand pile yarn produced in accordance with the present inventionand further illustrating the change in yarn structure produced by thetransfer of a relatively heavy tensioning strain from one to an-v otherofsaid strands;

Fig. 2a is a diagrammatic opened-out view of a threestrand yarn similarto that illustrated in Fig. 2, but with the addition of a core yarn; Y

Fig. 3 is a photographic plan view of a section of a floor lcoveringproduced in accordance withthe invention; f

Fig. 4 is an isometric view of an overedge stitcher adapted for theforming of the enchained yarns of Figs. 1 and 2, the machine being shownin operation for the forming of a two strand yarn such asthat shown inFig.' l;

Fig. 5 is a rear elevationv of the machine shown in Fig. 4 illustratingparticularly the tensioning device for applying a heavy tensionselectively to one oftwo feeding yarns, the tension control solenoids,theelectrical timing unit for controlling the operation of thesolenoidsfand the auxiliary yarn draw-off unit connected to be ldrivenin timed relation with the operation of the stitcher; an'd Fig. 6 is asomewhat diagrammatic sectional view of a floor covering including thebacking material and a serie of pile loops of the yarn shown in Fig. 1.v f

Referring to the drawings, Fig. 1 illustrates diagram--r matically, andwiththe loops loosely 4 intermesh'ed for purposes `of illustration, atwo-strand enchained pile Vescasos yarn made in accordance with theinvention having novel and improved characteristics which adapt the yarnespecially for use in the manufacture of loop pile fabrics. The yarn`shown in Fig. 1 consists of two strands, a white strand and a blackstrand 12, which are formed into a series of loops of which each loop ofone strand is enchained with a next succeeding ioop of the other strand.The white strand 10 in the left hand portion of Fig. 1 is formed intorelatively small tight loops 14 which appear at spaced intervals alongthe length of the yarn. The black strand 12 is drawn into long looselyformed loops 16 which lie in a direction generally inclined toward theaxis of the yarn. The stitches, each of which consists of one loop ofthe white strand 10 and one loop of the black strand 12 enchainedtherewith are preferably of a length to form from three to six stitchesper inch, although a greater variation, as for example from two toseven stitches per inch, is permissible if desired, depending upon thematerial used. In appearance, the yarn is constricted at the location ofeach tight loop 14 but tends to lie loosely between the loops 14imparting an appearance of looseness to the yarn as a whole. lt will benoted from an inspection of the left portion of Fig. 1 that there are,between succeeding tight loops 14, three connecting links of the blackstrand .and one connecting link of the white strand. This portion of theyarn formed with the tightly tensioned white strand 10 and the looselytensioned black strand-12 is predominately black in color but with whitestreaks formed therein as shown, for example, in the dark areas of Fig.3.

As hereinafter more fully set forth, the peculiar loop structure shownin the left hand portion of Fig'l is produced on an overedge stitcherhaving a needle, an upper looper, a lower looper, a mandrel about whichsuccessive stitches are formed, and a draw-off device by means ofwhichthe completed yarn is drawn-oit at a rate determined in accordance withthe number of stitches called for per inch.

Passing from the left to the right hand portion of Fig. 1 the tensionuponY the feeding white strand 10 has been reduced and a heavy tensionis now automatically applied to the feeding -black strand 12, so thatthe black strand is caused to form tight loops 18 spaced a stitch lengthapart along theV yarn. The loops 1S are connected by a loop 20 and anadditional connecting link of the white strand extending in a directionsubstantially lengthwise of the completed yarn so that betweensucceeding tight loops 18 there are provided three connecting links ofthe white strand and one connecting link of the black strand, thusgiving the portion of the yarn shown in the right hand portion of Fig. 1a predominately white color, but streaked with black, as shown in thelight areas of Fig. 3.

As previously pointed out, Fig. l is a somewhat diagrammatic disclosureof applicants novel enchained yarn. An artists representation of thetwo-strand yarn shown in Fig. Yl with the white strand predominating, isshown in'Fig. 4, anda photographic representation of the twostrand blackand white yarn as embodied in a door coveringrhaving a looped pilesurface is shown in Fig. 3.

n Theenchained yarn formed in the manner above described has been foundto have a number of unusual and useful characteristics which adapt theyarnY particularly for use as a pile yarn in a loop pile fabric. Thestrands are very .firmly secured together at intervals by the tightlydrawn loops of the one strand while at the same time a loose flowingappearance of the pile surface loops is provided by the relatively longconnecting links extending between the successive tightly drawn loops ofthe one strand. The structure of the 'enchained `yarn is such thatbreakagerof any one of the strands at any point will have no seriouseffect upon adjacent portions of the yarn,

as there is no tendency of a severed strand to pull or ravel.

The physical structure of the yarn has made it possible to employmaterials which would not ordinarily be considered adaptable for use inthe manufacture of a loop pile fabric, for example a synthetic fibersuch as filament rayon, which is both smooth and slippery and tends tobe caught and Vpulled during actual use. A continuous filament syntheticliber when incorporated into applicants enchained yarn structure is tiedtogether so rmly, iirst by the enchaining of the strands and further bythe insertion of the tightly drawn loop in each successively formedstitch, as to substantially eliminate the objections above noted, whileat the same time the relatively loose arrangement of the strand linksbetween the tightly drawn loops in the yarn imparts a relatively sottand nely bered appearance to the looped pile surface of the fabric.

A further novel characteristic of the improved pile yarn structureshown, which is of particular advantage for use as a pile yarn in themanufacture of lloor coverings having a loop pile surface, consists inthe highly resilient, non-crushable quality of the looped yarn whichwhen released tends quickly to return to its initial position.

Fig. 2 is a disclosure of a three-strand enchained yarn, each strandbeing formed into a series of loops of which each successive loop isenchained with the next succeeding loop of an adjacent strand inrotation. For convenience of illustration, strands of three differentcolors are shown including a white strand 24, a black strand 26 and athird strand 28 which may be either the same or a different color fromeither of the other strands. In the left hand portion of Fig. 2, theyarn is enchained together or stitched under conditions in which arelatively heavy tension is applied to the white strand 24 and arelatively light tension is applied to the darker strands 26'and 23. Theloops 30 of the white strand 24 are thus drawn in tightly-whereas theloops 32, 34 formed from both of the other strands and subiected to anormally light tension, lie in a generally parallel relation lengthwiseof the completed yarn. The right hand portion of Fig. 2 illustrates acondition in which the heavy tension or resistance applied to the whitestrand 24 has now been transferred to the dark colored strand 26 causingloops 35 formed from the strand 26 to be drawn in tightly, and causingloops 3S, 4t) formed from strands 24 and 23, to be formed loosely.

The three-strand yarn of Fig. 2 has substantially the advantages of thetwo-strand yarn shown in Fig. 1 in that the colored strand to whichheavy tension is applied is subordinated, permitting the remainingstrand color or colors to become predominant. The enchaining process andthe drawing in of the loops made from one strand combine to produce astable resilient pile yarn, and one in which increased bulkiness isimparted to the yarn.

, it will be observed that in the two-strand yarn of Fig. l

the legs of the successively formed loops provide the equivalent of fourstrands, and in the three-strand yarn of Fig. 2 the legs of thesuccessively formed' loops provide theV equivalent of tive strands. Thephysical structure of the yarn combined with color variation from onestrand to another serves also to provide a pile yarn having unusualcolor and textural characteristics. The stitches formed from thethree-strand yarn are preferably of a Vlength to form from'two to sixstitches per Y inch. although greater variation may be permissibledepending upon the material used.

Figs. la and 2a of the drawings are disclosures of twoand three-strandyarns similar toy those illustrated in Figs. l and 2, but with theaddition of a heavy core yarn 22. In the formation of the yarn shown inFig. la the strands 10,:12 are enchained around an anvil in the samemanner as in the formation of the two-strand yarn illustrated in Fig. 1hereinafter` specifically described.Y Thel core yarn is preferably fedthrough a hole Vformed in the center of a specially constructed anvil.The feeding of the yarn causes the enchained strands to be drawn ontoand tightened about the core 22. By substantially increasing the tensionon one or the other strand the same color variation along the length ofthe yarn is produced as in the case of the two-strand enchained yarn ofFig. l. l

The cored three-strand yarn of Fig. 2a is formed in the same manner asthe three-strand enchained yarn above described and illustrated in Fig.2, but with'the addition of the core yarn 22 which is preferably fedthrough a centrally located aperture in a specially constructed anvil.Variation in the tension on the feeding strands causes color variationsto appear along the length of the cored yarn in the same manner as thatset forth in the formation of the three-strand yarn of Fig. 2. The coredyarn has the specific advantages of greater weight, exceptional strengthand resistance to stretch, which are in addition to the advantagespreviously noted for the three-strand enchained yarn of Fig. 2.

It will be understood that the invention in its broadest aspects is notlimited specifically to the yarn structure illustrated, but it willinclude multiple strand enchained yarns in which the strands aredistinguishable from each other by physical characteristics other thancolor, or in which strands having different dye absorbingcharacteristics are employed, the differences in color to be brought outonly when the fabric woven from the yarn is linally dyed. Fig. 3 shows asample of a tufted oor covering having a looped pile surface producedwith the enchained pile yarn specifically illustrated in Figs. 1 and 4of the drawings in accordance with the invention. It will be understoodalso in accordance with the invention, that pile yarns having threeenchained strands as shown in Fig. 2, and core yarns having a corestrand and two enchained strands as shown in Fig. laor a core strand andthree enchained strands as shown in Fig. 2a, may be drawn as loopsthrough the fabric to produce a pile tufted iloor covering in manyrespects similar to the tufted pile fabric shown in Fig. 3. The sampleshown comprises specifically a woven backing material through which aredrawn series of loops of the enchained pile yarn. t The tuftingoperation is carried out in a well known manner on a tufting machinewhich may have from one to several scores of tufting needles, eachthreaded with a separate pile yarn and driven in unison to passsuccessive groups of loops through the backing material from back tofront. Loopers cooperating with the respective needles and located atthe face side of the work are arranged to engage with and retain therespective pile loops as the needles are withdrawn preparatory to theformation of the next stitch.

It will be understood that a oor covering having a looped pile surfacein accordance with the invention may be produced in other well knownways, as for example by a weaving operation in which the pile loops areformed from pile warps comprising the enchained pile yarns hereindescribed which are raised over pile wires.

The floor covering produced in accordance with the invention having theloop pile surface thereof formed from applicants novel enchained pileyarn as above described has novel and desirable characteristics from thestandpoint of both construction and appearance. As will readily be seenfrom an inspection of the photographic Fig. 3, the individual strandsforming each yarn are plainly visible and impart to the loop pilesurface the appearance of a finely woven fabric, while at the same timethe individual loops, being tied firmly together at intervals by thetightly drawn loops of the tensioned strand, have a wholly unexpectedrmness and a resiliency which 'prevents the pile surface from beingcrushed or matted "6 Y as a result of continuous use. The yarn, beingrelatively bulky and comprised of strands which tend to balloon betweenthe successive tightly drawn tying-in loops, provides a very goodcoverage even though a relatively coarse gauge is employed in thespacing of the individual loops and rows of loops. v

A further outstanding characteristic of the floor `covering shown forexample in Fig. 3 is the characteristic appearance which is achieved bythe enchaining together of strands of two different colors which in thesample shown may be black and white. As previously noted and ashereinafter more fully set forth in connection with the method ofmanufacture employed, the subjecting of any one of the feeding strandstov a relatively heavy tension has the effect of causing the other lessheavily tensioned strands to appear predominately in the completed yarn.In the disclosure of Figs. 1, 3 and 4 each enchained pile yarn is madeup of a black and a-white strand, of which one strand is tensionedduring the stitching or enchaining of a predetermined arbitrary lengthof the enchained pile yarn, and thereafter the other strand is similarlysubjected to a heavy tension during the stitching or enchaining ofa'further arbitrary length of the enchained pile yarn, so that in thetufting operation a series of pile loops are formed in which rst one andthen the other color predominates to produce the scatter pattern effectshown in Fig. 3. A further-outstanding characteristic of the pilesurface formed with applicants improved yarn consists in the peculiarmixture of colors produced by the enchaining process whereby the areaspredominantly white in color show also traces of black throughout thearea, and the areas predominantly black in color similarly show tracesof white. A unique texture and gradation of color from light to dark inthe looped pile surface is thus obtained which is both soft andpleasing.

The improved pile yarn above described is produced by a novel andimproved method of enchaining together the individual differentlycolored strands. The enchained yarn is preferably produced on aconventional overedge stitcher of the general type having a curvedstrand-carrying needle and an upper looper and a lower looper, eachapertured to receive a feeding strand. For the making of two-strand yarnthe lower looper only' is formed as a strand carrying looper. The stitchforming mechanism described, when operated without work Vin the machineforms a thread chain in which a loop -of one strand is drawn through aloop of another strand which is in turn drawn through a new loop of thefirst strand, or through a loop of the third strand if three strands areused, in continuous rotation. Inasmuch as stitchers of' the general typereferred to, including a curved needle and upper and lower loopers, arewell known in'the art, specific illustration or description of thismechanism is believed unnecessary. For a more' complete description of amachine of the general type illustrated reference may be had to thepatents to Steadman No. 733,760 and Washburn 1,966,367.

It will be understood that the illustrated machine differs from thoseshown in the prior art specifically in the omission of the usual worktable, feed dog and presser foot mechanisms adapted for supporting andfeeding work in the machine.

Referring specifically to Figs. 4 and v5 of the drawings, an overedgestitcher of the general type referred to is shown comprising a base 42and a housing 44 within which are mounted the supporting and actuatingmechanisms not shown. The machine is provided with a curved eye needle46, an upper looper 48 and a lower looper 50. The needle 46 is mountedon a rocker arm A52 arranged to oscillate about a pivotal support notspecifically shown. In place of the usual work support and feed dog theillustrated machine is provided with a chainforming mandrel 54. '.Asbest shownin Fig..4',-the mandrelw54takes the form of a horizontallydisposed member having a't'apered'end portion extending generally in thedirection of feed wwithl relation to the stitching devices. The mandrel54 is adjustably secured by a clamping screw 56 in a guideway S8 on abracket 60 carried on the base 42. The tapered end of the anvil member54 is located with relation to the stitch forming devices so that theneedle, moving forwardly and downwardly, passes across the front face ofthe mandrel 54, the lower looper passes transversely beneath the mandrel54, and the upper looper moves in a generally vertical direction acrossthe rear face of the mandrel S4. The machine is shown as set up fortheforming of a two-strand enchained yarn. The strand 12 is threadedthrough the eye of the needle 46. Thestrand is threaded through an eyein the lower looper S0.

In accordance with the present invention a novel tensioning mechanism isprovided for applying a relatively heavy` tensionY selectively to one orthe other of the two feeding strands. The strand 12 threaded through theneedle `46 may correspond with the black strand 12 of Fig. l and thestrand threaded through the lower looper 50 may be taken as the whitestrand 10 of Fig. l. The

two strands as shown in Figs. 4 and 5 are drawn from supply throughindividual solenoid controlled tension devices mounted in an openhousing 70 on a frame 72 carried by the base 42, through the usualtensioning devices designated respectively at 74, 76 on top of themachine, and thence through guides and take-up devices which may be ofordinary construction to the needle 46 and lower looper 50 respectively.

The solenoid controlled tension devices provided in accordance with theinvention comprise specically two xed friction disks 78 and 80 whichcooperate respectively with two movable tension disks 82 and 84. Formoving the tension disks 82, 84 into and out of operative position,solenoids 86 Vand 88 are mounted on the skeleton housing 70 witharmature shafts 90, 92 which are connected respectively to moveabledisks 82, 84.

The solenoids 86, 88 are caused to operate alternately so that one ofthe friction disks 82, 84 is moved to an inoperative position while theother of said disks is released to engage with and apply a heavytensioning strain to its feeding strand. The lirst solenoid is thendeenergized and the second solenoid is energized to cause a heavytensioning strain to be applied to the first strand, and to release thetension on the ground strand. The operation of the solenoids iscontrolled by an electrical timing device which may be of ordinarydescription and which leads into a switch secured to the top of theframe 70. The timing device is set to cause each solenoid in turn to beenergized for a predetermined length of time. Assuming a rate ofoperation ofthe machine at 4500 revolutions per minute, an adjustment ofthe variable yarn draw-off mechanism 120, hereinafter referred to, toproduce approximately 4 stitches per inch of yarn, and the length ofyarn in which one color predo'minates to be Y between 40 and 50 inches,the time interval between successive operations of the timing device,when each solenoid isv again energized or de-energized, will be in theneighborhood of 21/2 seconds.

As shown in Figs. 5 and 4, the strand 12 drawn from supply passesthrough a guide 96, between disks 84, 80 of the solenoid controlledtension device, thence through a guide 98 on the casing 44, through theusual tension 74 on top of the machine, through eyes 100, 182 on astationary bracket 1.04, and through an eye 106 of an interposed take-uparm 108, and thence tothe needleV 46.

, Strand 10 drawn from supply passes through a guide 110 between thedisks 78, 82 of the solenoid control tension device, through the usualtension 76 on top of the machine, and thence downwardly and upethroughVthe bracket to thelowerlooper. Y

Y The. enchaitiedv yarn producedby vthe operation of, the

stitching mechanism its drawn ott between a Pair of drawoif rolls 1 16,118 which are .positively driven at a rate related to the speed at whichthe stitching mechanism is driven to produce a desired number ofstitches per inch. The rolls 116, 118 are mounted on output shafts of avariable speed drive unit which is generally designated at 120'in Fig.Y5 mounted on the base 42 of the machine. An input shaft 122 of thevariable speed unit 120 carries a pulley 124 which is driven from a maindriving belt 126 passing also around a driving pulley 128 carried on themain drive shaft 130 of the stitcher. Any desired variation in thenumber `of stitches per inch in the enchained yarn 132 is effected by asimple pulley change on the variable speed unit. Inasmuch as thevariable speed unit is of a type well known in the art it is believedunnecessary to show this mechanism in detail. A continuous even tensionis maintained on the enchained yarn 132 drawn off from the machine bythe rolls 116, 118, a guide 13.4 being used to control the direction ofthe yarn drawn from the forming mandrel 54 by the drawotf rolls 116,118.

The invention having been described what is claimed 1s:

l. A pile yarn comprising two strands having dierent colorcharacteristics, each strand being formed into a series of loops, ofwhich each loop of one strand is enchained with the next succeeding loopof the other strand forming a series of lock stitches evenly spacedalong the length of the yarn, predetermined lengths of said yarn havingthe loops of one strand tightly formed and the loops of the other strandloosely formed to provide a substantial preponderance of the looselylooped other strand and a preponderance of the associated color charac-`teristic in Ysaid lengths of the yarn, and other lengths of said yarnhaving the loops of said one strand loosely formed and the loops of saidother strand tightly formed to produce a substantial preponderance of'said loosely looped one strand and a preponderance of the associatedcolor characteristic in said other lengths of the yarn.

2. A pile yarn comprising a plurality of strands, each strand beingformed into a series of loops of which each loop of each strand isenchained with a loop of another strand in rotation to form a series oflock stitches evenly spaced along the length lof the yarn, predeterminedlengths of said yarn having the loops of one strand tightly formed andthe loops of the other strands loosely formed to provide a substantialpreponderance of said loosely looped other strands in said lengths ofthe yarn, and other lengths of said yarn having the loops of anotherstrand tightly formed and the loops of the remaining strands looselyformed to obtain a substantial preponderance of said loosely loopedremaining strands in said other lengths of the yarn.

3. A pile yarn comprising three strands including at least two strandswith different color characteristics, each strand beingformed into aseries of loops, of which each loop of each strand is enchained with thenext succeeding loop of another strand in rotation to forma series oflock stitches evenly spaced along the length of the yarn, predeterminedlengths of said yarn having loops of a strand with onepcolorcharacteristic tightly formed, and having the loops ofthe other strandsloosely formed to provide at substantial preponderance of the saidloosely looped other strands and a preponderance of the associated colorcharacteristic in said lengths of the yarn, and in other4 lengths ofsaid yarn having the loops of a strand with another color characteristictightly formed and the loops of the remaining strands loosely formed toobtain asubstantial preponderance of said loosely looped remainingstrands and a preponderance of the associated color characteristic insaid other` lengths of the yarn.

4. A' pile yarn comprising a plurality of strands of ilament` syntheticyfiber includingstrands of dierent'color characteristics, eachstrandbeing, formed into a series of loops ofwhch each. successively farmed1001 0f. each strand is enchained with a next succeeding loop of anotherstrand in rotation to form a series of lock stitches evenly spaced atthe rate of between two and seven stitches to the inch along the lengthof the yarn, predetermined lengths of said yarn having the loop of astrand with one color characteristic tightly formed, and having theloops of other strands loosely formed to provide a substantialpreponderance of said loosely looped other strands in said lengths ofthe yarn, and other lengths of said yarn having the loops of a strandwith a different color characteristic tightly formed, and having theloops of the remaining strands loosely formed to obtain a substantialpreponderance of said loosely looped remaining strands in said otherlengths of the yarn.

5. A pile yarn comprising a plurality of strands including a core yarnand at least two chain forming strands with different colorcharacteristics, each chain forming strand being formed into a series ofloops of which each successively formed loop of each chain formingstrand is enchained with the next succeeding loop of another chainforming strand in rotation about the core yarn to form a series of lockstitches spaced evenly at a rate chosen between two stitches and sevenper inch along the length of the yarn, predetermined lengths of saidyarn having the loops of one strand of said two chain forming strandstightly formed and the loops of the other strands loosely formed toprovide a substantial preponderance of said loosely looped other strandsand a preponderance of the associated color characteristic in saidlengths of the yarn, and other lengths of said yarn having the loops ofthe other of said two chain forming strands tightly formed, and theloops of the remaining chain forming strands loosely formed to provide asubstantial preponderance of said loosely looped remaining chain formingstrands and a preponderance of the associated color characteristic insaid other lengths of the yarn.

6. A pile yarn comprising a core yarn and three chain forming strandsincluding at least two strands with diierent color characteristics, eachchain forming strand being formed into a series of loops of which eachloop of each strand is enchained with the next succeeding loop ofanother strand in rotation about the core yarn to form a series of lockstitches evenly spaced along the length of the yarn at a rate chosenbetween two and seven stitches per inch, predetermined lengths of saidyarn having loops of a strand with one color characteristic tightlyformed, and having the loops of the other strands loosely formed toprovide a substantial preponderance of said loosely looped other strandsgrouped about the core yarn and a preponderance of the associated colorcharacteristic in said lengths of the yarn, and in other lengths of saidyarn having the loops of a strand with another color characteristictightly formed and the loops of the remaining strands loosely formed toprovide a substantial preponderance of said loosely looped remainingstrands grouped about the core yarn and a preponderance of theassociated color characteristic in said other lengths of the yarn.

7. A oor covering comprising a 1backing material and a loop pile surfaceof multi-colored pile yarn comprising at least two strands withdifferent color characteristics, each strand being formed into a seriesof loops of which each loop of each strand is enchained with the nextsucceeding loop of another strand in rotation to form a series of lockstitches evenly spaced along the length of the yarn, the yarn formingsome of said pile loops having the loops of a strand with one colorcharacteristic tightly formed and the loops of said other strandsincluding the strand with a different color characteristic looselyformed to provide a preponderance of the loose strands and of saidassociated different color characteristic in certain of said pile loops,and other pile loops of said fabric having the loops of said strand withthe diterent color characteristic tightly formed and the loops of theremaining strands -including the strand 10 s with said one colorcharacteristic loosely formed to v obtain a substantial preponderance ofsaid loosely looped remaining strands and of said associated colorcharacteristic in said other pile yloops of the floor covering.

8. A iloor covering comprising la backing material and a loop pilesurface of multi-colored yarn composed of differently colored strands,each strand being formed into a series of loops of which each loop ofeach strand is enchained with the next succeeding loop of another strandin rotation to form a series of lock stitches evenly spaced along thelength of the yarn, lengths of said yarn forming some pile loops havingthe loops of one strand tightly formed and the loops of the remainingstrands loosely formed, and other lengths of said yarn forming otherpile loops having the loops of another of said strands tightly formedand the loops of the remaining strands loosely formed to obtain asubstantial preponderance of first one and then another colorVcharacteristic in said respective lengths of yarn and in the pile loopsformed therefrom.

9. A floor covering -comprising a backing material, and a loop pilesurface of multi-Stranded yarn composed of a plurality of strands ofcontinuous filament synthetic iiber, each strand being formed into aseries of loops of which each loop of each strand is enchained with thenext succeeding loop of another strand in rotation to form a series oflock stitches evenly spaced and numbering between two and seven to theinch along the length of the yarn, and with the loops of one strandtightly formed, and with the loops of any remaining strand looselyformed to obtain a substantial preponderance of said loosely loopedother strands in said yarn, and a periodic tight binding of said strandsinto said yarn.

l0. A iloor covering comprising `a backing material, and a tread pileloop surface of multi-colored yarn composed of lament synthetic libershaving different color characteristics, each strand being formed into aseries of loops of which each loop of each strand is enchained with thenext succeeding loop of another strand in rotation to form a series oflock stitches at the rate of 3 to 6 to the inch evenly spaced along thelength of the yarn, lengths of said yarn forming selected pile loopshaving the loops of one strand tightly formed and the loops of theremaining strands loosely formed, and other lengths of said yarn formingother pile loops having the loops of -another color tightly formed andloops of the remaining strands loosely formed to obtain a substantialpreponderance of iirst one, and then another color characteristic insaid respective lengths of yarn and in the pile loops formed therefrom.

- ll. A oor covering comprising la backing material and a loop pilesurface of multi-col-ored pile yarn comprising a plurality of strandsincluding a core strand and at least two chain forming strands ofdifferent color characteristics, each chain forming strand being formedinto a series of loops of which each loop of each chain formlng strandis enchained with the next succeeding loop of another chain formingstrand in rotation about said core strand to form a series of lockstitches evenly spaced along the length of the yarn, the yarn formingsome of said pile loops having the loops of one chain forming strandtightly formed and the loops of any remaining chain forming strandloosely formed to provide a substantial preponderance of said looselylooped remaining chain forming strand and of the associated colorcharacteristic in said pile loops, Iand other pile loops of said fabrichaving the loops of another chain forming strand tightly formed and theloops of lany remaining chain forming strand loosely formed to obtain asubstantial preponderance of said loosely looped remaining strand andYof the associated color characteristic in said other pile loops of thefloor covering.

12. The method ofV forming a multi-colored pile yarn having a variablecolor characteristic along its length, which comprises' the steps ofcombining a plurality of strands including lock stitching together atleast two chain forming strands of dierent color characteristics arounda chain-forming mandrel, drawing oi the yarn so formed with relation tothe lock stitching at a rate of at least two stitches per inch andselectively applying a heavy resistance to one only of said chainforming strands to cause said chain forming strand to form tight loopsand any other chain forming strand to form elongated loosely formedloops, and shifting said heavy resistance from one to another chainforming strand in rotation to cause each of said chain forming strandsin turn to form tight loops and any remaining chain forming strand toform elongated loosely formed loops, and therebyto produce a substantialpreponderance of diierent chain forming strands and correspondingydifferent color characteristics in different lengths of the said yarn.

13. The method of forming a multi-colored pile yarn having a variablecolor characteristic along its length which comprises the steps of lockstitching together a plurality of strands including 'at least two chainforming strands of dilerent color characteristics around a core strandon a chain-forming mandrel, drawing off the cored chain yarn so formedwith relation to the lock stitching at a rate of atleast two stitchesper inch and selectively applying a heavy resistance to one only of saidchain forming strands to cause said strand to form tight loops and'anyremaining strand to form elongated loosely formed loops about saidcore, and shifting said heavy resistance in rotation from one to anotherchain forming strand to cause each chain forming strand in turn to formtight loops and any remaining strand to form elongated loosely formedloops, and thereby to produce a substantial preponderance of differentstrands and corresponding different color characteristics in differentlengths of said yarn.

References Cited in the file of this patent UNITED STATES PATENTS1,802,337 Decker et al Apr. 28, 1931 1,825,454 Haussler Sept. 29, 19311,860,030 Hinchliir May 24, 1932 2,137,692 Linke Nov. 22, 1938 2,297,061Knaus Sept. 29, 1942 2,316,060 Fullerton et al. Apr. 6, 1943

